JP2003525802A - End of vehicle carrier and method of manufacturing the same - Google Patents

Abstract

(57) [Summary] The present invention includes a plurality of downwardly open groove-shaped ribs (18) extending in the longitudinal direction of a carrier member and terminating at front and rear ends, and is formed by roll forming. And an integrated vehicle carrier member (11). The integrally formed vehicle bed member (11) is formed by deforming the vicinity of one end of the rib (18), inclining downward from the upper surface of the rib (18), and connecting to the flat end flange (31) in the width direction. (32) is formed. The center surface of the tapered rib portion (32) is offset downward from the projection (38) connecting the center surface portion and the side surface of the rib.

Description

Detailed Description of the Invention

TECHNICAL FIELD [0001] The present invention relates to a carrier member for a vehicle such as a truck in which longitudinal ribs and valleys are alternately roll-formed, and particularly, ribs near the end of the carrier are longitudinal. TECHNICAL FIELD The present invention relates to a luggage carrier member having an improved tapered end portion structure of ribs which is connected to a plane which is tapered downward to form a luggage carrier bottom portion.

BACKGROUND OF THE INVENTION The assignee of the present application has developed a truck carrier structure and a forming method thereof to improve the structure of a truck carrier member formed by a conventional stamping method. It is US Pat. Nos. 5,188,418, 5,544,932, 5,525,525, 5,73048.
6, No. 5,938,272, No. 6,128,815. All of these are assigned to Pullman Industries, Inc. and are included in the disclosure for reference.

In the aforementioned patent, as shown in FIG. 1, a main floor pan or a luggage carrier member 11 mainly developed for a pickup truck is disclosed. The carrier member 11 is arranged between the side walls 12 of the truck, and the front sill 14 to the rear sill 14
Has been extended to. The rear end of the carrier member is fixed to the rear sill 14, usually by welding. The carrier member 11 is supported and fixed by longitudinal sills such as an intermediate lateral sill 15 and a front sill 16, which are spaced apart in the longitudinal direction. The carrier member 11 has a rib 18 having a groove-shaped cross section.
-Valley portions 19 are alternately arranged in the longitudinal direction of the thin plate and are roll-formed from a continuous steel thin plate. Then, the roll-formed thin plate is cut so as to have the length of the carrier member, but the front and rear ends of the carrier member have a corrugated shape because ribs and valleys are alternately provided. In a preferred modification according to the present invention, a protrusion 17 is formed on the upper surface of the rear sill 14. The projecting portion 17 is fitted with a trough portion of the rear end of the luggage carrier member 11 after the rear end of the rib is cut off to strengthen the structural assembly.

The above arrangement, shown schematically in FIG. 1, is a highly desirable carrier assembly. However, in order to meet the various needs of using such vehicles, the assignee is
The structure of the carrier member 11 has been improved and developed. As shown in FIGS. 2-5, the ends of the ribs 18 are flattened downwards through tapered (tapered) or downwardly sloping ribs to form the bottom (i.e. the bottom of the trough) of the carrier member. Face). There, the rib ends are terminated and the ends of the carrier members are substantially flat.

Co-filed US patent application Ser. No. 09/196979 (currently superseded by co-filed US patent application Serial No. 09/611444), incorporated herein by reference. 2 to 5, the structure is disclosed. That is, a roll-shaped carrier member in which a carrier end is supported by a conventional lateral sill 21 (rear or front sill) without providing a protrusion on the upper surface of the sill that fits with a valley of a rib. It is the improved end of eleven. However, such sill protrusions are still preferred. In this end structure, the carrier member 11 is provided with a substantially flat flange 22 extending across the width of the carrier member and terminating in a free end 23 of the carrier member. The flange 22 is formed by deforming and flattening the rear portion of the groove-shaped rib 18 from the free end 23 to the front over a predetermined length in the longitudinal direction.

Further, the rib 18 of the luggage carrier member 11 in FIGS. 2 to 4 (just in front of the flange 22)
Is deformed downward to provide the tapered rib portion 18A. The taper rib portion 18A is
It extends a short distance in the longitudinal direction of the carrier member and constitutes a transition area between the rear flange 22 and the longitudinally extending full-height rib 18. Taper rib part 18
The end of the upper surface 25A of A is continuously joined to the upper surface 25 of the rib 18 having the full height. Then, the upper surface 25A is bent or inclined downward as it extends in the longitudinal direction, intersects with the bottom surface 26 of the luggage carrier member, and forms the bottom of the valley 19. The intersection substantially constitutes the transition between the tapered rib 18A and the rear flange 22. In this way, the tapered rib portion 18A becomes an inclined surface or an inclined path that projects upward from the height of the bottom surface 26 or the flange 22 to the height of the rib upper surface 25. If the tapered rib portion is at the rear end of the carrier member, its ramp projects longitudinally, i.e., slopes upward, which is the forward forward direction of the carrier member. Thereby, sharp or sharp corners at the rear end of the carrier member are eliminated or minimized.

The tapered rib portion 18A is formed by physically deforming the rib 18 having a predetermined length and a complete height into a shape that is tapered or inclined downward. The physical forming is generally performed by a shape press after roll forming the carrier member. When the rib 18 is deformed (that is, pressed) into a tapered shape, at least a part of the side surface 27 of the rib is crushed. Then, in order to minimize the material used when compressing the ribs into a tapered shape, the upper surface 25A of the tapered rib portion 18A is at least about 30 degrees with respect to the horizontal direction, and more preferably from about 40 degrees to about 45 degrees. It is preferable that the inclination or angle is moderate.

[0008] The ends of the ribs 18 are deformed to form the tapered ribs 18A, but at the same time as the deformation or pressing work, that is, the rib ends of the portion of the entire length of the flange 22 in the longitudinal direction are flattened to form a bottom surface. Simultaneously with the deformation or pressing operation of forming the substantially flat end flange 22 so as to be substantially flush with 26, the end portion of the rib 18 extending between the tapered rib portion 18A and the rear end 23 is also flattened. .

As shown in FIG. 2, the flange 22 is disposed on the upper surface of the horizontal sill and is fixed thereto.

Alternatively, the flattened rear flange (22A in FIG. 5) is replaced by the tapered rib portion 18
It may be bent downward near the intersection with A or slightly behind it. That is, when the lateral sill 21 is the rear sill of the vehicle carrier structure, the flange 22A projects downward (and therefore overlaps with the side surface) from the vicinity of the side surface such as the rear side surface that supports the lateral sill 21. In this case, the flange 22A is fixed to the lateral sill by welding, for example.

The rib end structure shown in FIGS. 2-5 is desirable in certain applications. However, even rib end structures made from such roll-formed carrier members have the undesirable result of wrinkling of the material during deformation or flattening operations. When a full height rib is transformed into a tapered rib and / or into a flat end flange, there is excess material due to the side surfaces 27 where the material is distributed to join with the adjacent top surface 25 and bottom surface 26. Because of this extra material, stamping the rear ends of the ribs usually does not effectively redistribute the extra material. Therefore, the taper rib portion 18A, and especially the flat end flange 22 near its flanks, and particularly where the rib flanks 27 were present, often suffers from significant wrinkling due to the extra material. Therefore, due to the surface structure, not only the required uniform thickness cannot be achieved, but also the surface characteristics are unfavorable especially when coating is applied.

DISCLOSURE OF THE INVENTION Accordingly, the present invention firstly roll-forms and then the shape of the tapered end (FIGS. 2-5).
The shape of the taper rib end and the forming process are improved in the structure of the load carrier member that is formed by, for example, pressurizing so as to have the same shape as the above. That is, by deforming the ends of the roll-formed ribs by stamping or the like, and by using the improved structure and method, it is possible to more effectively redistribute excess material during the deformation work, which is not preferable. It completely eliminates or minimizes the occurrence, and further increases the strength and rigidity of the tapered rib portion.

The improved structure according to the invention and the advantages resulting therefrom will be immediately apparent from the following specification and the accompanying drawings.

BEST MODE FOR CARRYING OUT THE INVENTION Certain terminology is used in the following description, which is for convenience and reference only and not limitation. For example, "up", "down", "right"
The term "to the left" is with respect to the referenced drawing. "Inward""
The words "outward" refer to the center of the carrier member and the target component, respectively.
It means away. Such terms include words that are specifically identified, derivatives, and similar terms.

FIG. 6 shows an integrated structure in which a thin metal sheet in which groove-shaped ribs 18 having an open bottom are formed in parallel and oriented in the longitudinal direction is roll-formed. A part of the vehicle carrier member 11 is shown. Valleys 19 are provided between the ribs 18. In the cargo carrier member improved by the present invention, the rib 18
At least one end of which is joined to the flat end flange 31. Similar to the configuration according to FIGS. 2 to 5, a tapered rib portion 32 is formed on the rib 18. However, both the tapered rib portion 32 and the end flange 31 are shaped so as to supplement the extra material.
The extra material, which occurs when flattening the ends 35 of the ribs 18, eliminates or at least minimizes wrinkles in the tapered ribs 32 or end flanges 31 due to such shape.

In the structure improved by the present invention, the upper surface of the tapered rib portion 32 is provided with a shallow recessed portion 33 that is lowered (offset) downward from the upper surface and side surfaces thereof. Further, the end flange 31 coupled to the taper rib portion is offset upward over a predetermined length in the longitudinal direction, and the recess 34 is formed therein. These recesses 3
Nos. 3 and 34 are molded almost simultaneously with the flattening / deforming work of the rib end portions.
The flattening operation basically relates to the rib portion (shown by the dotted line 35 in FIG. 7) extending to the free end of the luggage carrier member. When the rib end portion 35 is flattened to form the taper rib portion 32 and the flat end flange 31, the recess 33 is formed on the upper surface of the taper rib portion 32 and the end flange 31 with a molding die or a pressing die at substantially the same time.
Is configured to form a recess 34 adjacent the.

With respect to the structure of the tapered rib portion 32, the tapered rib portion 32 has a rib 18 in the longitudinal direction.
Is connected to the upper surface 25 of the tapered rib portion 3 when the rib end portion 35 is deformed.
2 and the upper surface 25 are formed so as to bend downward, and through the shallow S curve curved portion 36 which is a curved portion in a substantially opposite direction, a substantially flat tapered rib portion 3 which is inclined downward.
It connects with the inclined end surface 37 of 2. The substantially flat inclined end surface 37 is formed by the protrusion end portion 38.
It extends in the width direction (that is, sideways). The projecting end portion 38 is inclined downward from the joining point with the rib upper surface 25 and is in a position parallel to the inclined end surface 37. The protruding end 38 extends generally along the rib flank 27 and joins with the flat end flange 31 at a location longitudinally spaced from the free end 39 of the flange. Since the protruding end portion 38 projects above the tapered inclined end surface 37, the recess 33 that is offset downward is formed between the end portions. The protruding end portion 38 has an arch shape with a substantially rounded top, and connects the inclined end surface 37 and the rib side surface 27. Recess 33
An arched protrusion end 38 is formed by the tapered inclined end surface 37 offset downward. As a result of the protruding end portion 38 having an open bottom groove or a U-shape, extra material is required there. Therefore, supplement it with extra material generated during deformation.

Further, when the tapered rib portion 32 is formed as described above, the rib end portion 35 is formed.
When deformed, the flat end flange 31 is also molded at the same time. Also, the end flange 31 also deforms substantially at the same time to form a recess 34 therein to form a raised surface or platform 41. The platform 41 is joined to the lower end of the taper inclined end face 37, extends toward the end flange 31 side, and is separated from the free end 39 in the longitudinal direction by the rear end 4.
It ends in 2. The width of this platform 41 in the exemplary embodiment is
It is preferable that the lengths 8 substantially match the lengths between the lower ends of the protrusions that are connected to the end flanges 31. The raised surface or platform 41 is preferably substantially flat and is raised from the end flange 31 substantially parallel to the end flange 31. The lateral end 43 of the platform 41 is substantially connected to the lower end of the tapered inclined end surface 37.

Although not shown here, in another embodiment, the distance between the lower ends of the protrusion ends 38 (measured in the width direction of the luggage carrier member 11) is such that the lower ends are more directly adjacent to the front surface of the platform 41. Configuration to be joined with the end (when further separated from the free end 39 in the longitudinal direction)
It is slightly shorter than.

When the platform 41 is formed in this manner, a substantially vertical rear end 42 and a lateral end 43 connecting the platform 41 and the end flange 31 are formed. These ends 42
, 43 requires extra material. Therefore, these ends 42,
43 will be molded with a large amount of excess material created when flattening the rib ends 35. Furthermore, these ends 42, 43 have a similar function to the groove-like protruding end 38 in that they perform the same function as a vertical rib which increases the durability and crush resistance of the entire tapered end of the rib. ing.

The rear end 42 of the raised platform 41 preferably terminates away from the free end 39 of the end flange 31. This allows the flat rear portion of the end flange 39 to be placed and secured directly to the upper surface of a sill similar to that of FIG. 2, leaving the end flange 31 with a generally flat rear portion extending across the entire rear free end 39. Is. If desired, as in FIG. 5, the flat rear portion of the end flange 31, that is, the rear portion of the raised platform 41, can be bent downwards to overlap the side surface of the sill and be fixed thereto.

In the embodiment of FIG. 6, the depth of the recess 33 is the same as the amount by which the inclined end surface 37 is offset below the standard inclination angle by bending the upper bending portion 36 in the opposite direction. is there. Further, the depth of the concave portion 34 formed under the platform 41 is set to be at least about 1.5 times the thickness of the thin plate material of the luggage carrier member, preferably more than that. Typically, the carrier member thickness is about 0.040 inches (1.016 inches).
Mm) and the depth of the recesses 33, 34 is 0.060 inch (1.524 mm).
Thus, it is considered that the rib end portion 35 has a length long enough to compensate for the extra material generated when the rib end portion 35 is flattened and deformed, and the wrinkle member is not wrinkled. Further, in this configuration, the vertical surface portion obtained by the side surface of the projecting end portion 38 and the platform ends 42 and 43 increases the cross-sectional area and the vertical cross-sectional area, thereby increasing strength and durability.

In the improved carrier member according to the present invention, the one-roll-formed carrier member can be molded so as to extend over the center portion of the truck carrier, that is, between the wheel rooms of the vehicle.
Alternatively, the integrally formed carrier member may be molded over the entire width of the truck carrier and cut from it to provide the wheel chamber. Both variants are disclosed in the assignee's earlier patents and are also included in the present invention. Further, the taper rib structure of the present invention is preferably used in combination with the rear sill of the vehicle at the rear end of the luggage carrier member. Of course, the improved rib end structure of the present invention is also applicable when used at the front end of the carrier member, either alone or in combination with the rib end structure at the rear end of the same or similar carrier members.

Now, FIG. 11 shows a vehicle carrier improved according to the invention, in particular a carrier member for achieving the molding of a carrier member according to FIGS. 6 to 10 with flat rear end flanges and tapered ribs at one or both ends. 2 schematically shows a molding process for use in the above.

That is, the forming step is provided with the supply unit 51 having a large spool 52 of a thin sheet metal such as a thin steel plate. The spool 52 is a supply stand 53
It is rotatably supported by. The sheet material S is withdrawn from the spool and fed to a conventional forming roll or mill 55 through a drive roller 54 that forwards a continuous thin sheet material S that is thin but wide. In the mill 55, a plurality of roller units 56 are continuously provided at positions adjacent to each other along the moving direction of the thin plate. And each roller unit 5
In general, the upper and lower rollers 6 are engaged with both facing surfaces of the thin plate S to deform the thin plate into a required shape. In the present invention, the forming roll machine 55,
In particular, the series of roller units 56 gradually act on the outer surfaces of the opposite surfaces of the thin plate to deform the thin plate, and when the thin plate is separated from the forming roll machine 55, a series of ribs 18 oriented substantially continuously in the longitudinal direction of the thin plate. To mold. Using this molding method, when the rib shape required for the luggage carrier member is formed into a thin plate, the thickness of the thin plate is highly uniform over the entire cross section of the thin plate. And, by doing so, a high level of strength, performance and beauty can be achieved.

The deformed thin plate S separated from the roller mill 55 has a continuous three-dimensional profile (contour), and is shown as P in FIG. Then, it is supplied to a cutting machine, that is, a shearing section 57, which cuts the continuous profile P into a workpiece (workpiece / work-in-process) W having a predetermined length. These workpieces W are sized to make up the individual carrier members. However, in the molding method of the present invention, the length of the workpiece W is slightly longer than the length of the finished product of the carrier member so that one end or both ends of the workpiece can be deformed as described below.

The ribs 18 of the workpiece W extend in the longitudinal direction over the entire length of the workpiece, and the front and rear ends of the workpiece W are wavy. The posterior and / or anterior ends of the workpiece are then subjected to a deformation operation to form an end with tapered ribs and a flat end flange, as in Figure 12. The work of deforming one end or both ends of the workpiece W is carried out by a forming / deforming press 59 schematically shown in FIG. The molding press 59 includes an upper molding die (mold) 61 and a lower molding die 62.
It is possible to move vertically from the closed deformation position as shown in FIG. 11 to the open position where the upper and lower molds are vertically separated. The end of the workpiece W is disposed between the upper and lower molds 61 and 62, receives the facing molding surfaces 63 and 64, and receives the workpiece W.
Is deformed.

Now, the ends of the deformed carrier member shown in FIG. 12, particularly the ends of the ribs 18 deformed to form the tapered rib portion 32 and the end flange 31, have substantially the same shapes as those shown in FIGS. There is. However, in the platform 41 of FIG. 12, the lateral end 43 of the platform is substantially aligned with the extension of the rib side surface 27, and the platform 41 is slightly higher and the width is slightly wider so as to effectively form the extension. The location is different. The tapered rib portion 32 and the end flange 31 shown in FIG. 12 are indicated by the same reference numerals as those in FIGS.

The shape of the molding press 59, and in particular of the upper and lower dies 61, 62, their cooperation and their engagement with the workpiece W are shown in FIGS.

As shown in FIGS. 13 and 14, on the upper molding surface 64 formed on the lower mold 62, there is a substantially flat plane 71, and an upward projection from the plane 71 and a space in a lateral direction substantially parallel to each other. A plurality of male support portions 72 that are substantially the same and are spaced apart are formed. The male support portions 72 are each provided with a main support portion 73 protruding upward. The main support extends parallel to the plane 71 and is configured to snugly engage and support the lower surface of the rib 18 when forming the workpiece. The valley portion 19 of the workpiece is supported by the flat surface 71 between the male supporting portions 72.

At one end of the main support portion 73 of each male support portion 72, an end portion 74 that shapes the bottom side shape of the tapered rib portion 32 is formed. More specifically, an inclined portion 75 is formed at the end portion 74 of each male support portion 72. The inclined portion 75 is coupled to the main support portion 73 and is also inclined downward from the inclined portion 75 to be coupled to the raised platform portion 76. The inclined portion 75 and the platform portion 76 are shaped so as to support and engage the rib surface of the workpiece during rib forming and deformation. Its shape is shown in FIG.
The rib portion 32 and the platform 41 are adjusted so as to have the same shape as the rib portion 32.

Further, in the lower die 62 arranged as an example, a shoulder portion 78 protruding upward is formed at a position apart from the platform portion 76 in the longitudinal direction. The shoulder portion 78 is used so as to abut the end of the workpiece W when the workpiece W is placed on the forming press 59.

Further, in the lower mold 62, a plurality of first and second material deformation contours 81, 82 are formed between the shoulder portion 78 and the end of the platform portion 76. These contours 81 and 82 respectively project from the plane 71 in opposite directions and are arranged alternately in a row extending in the width direction with respect to the direction of the male support portion 72 extending in the longitudinal direction.

More specifically, the male contour 81 constitutes a male portion or a protruding portion (that is, an anvil) protruding upward from the plane 71. These protrusions are formed separately from the respective male supporting parts 72, but are provided in alignment with the male supporting parts 72 in the longitudinal direction.
Each of the male contours 81 extends in the width direction, and the dimension thereof is substantially the same as the width of the male support portion 72. Further, the cross-sectional shape and size of these male contours 81 are adapted to coincide with the cross-section of the main male support portion 73 so as to overlap within the rib 18.

On the other hand, the female contour 82 is formed as a female portion or a recess protruding downward from the surface 72. The centers of these female contours in the longitudinal direction are aligned with the valleys formed between the adjacent male support portions 72. The female contour (or recess) 82 is
It extends to the longitudinal direction side of the support portion 72, and its width is almost the same as the width of the valley portion in the width direction.

More specifically, the shape of male contour 81 is defined by parallel female contours 82. The female contour 82 is joined to a substantially parallel end 84 through a round corner. The length of the end portion 84 substantially matches the width of the male supporting portion 72. The end portions 83 and 84 clarify the shape of the connecting portion of the male contour 81 with the flat surface 71, and thus form a rectangular shape perpendicular to the longitudinal direction of the male supporting portion 72.

The male contour (or projection) 81 projects upward from the ends 83 and 84. A convex outer surface 85 rounded in the width direction from the end portion 84 is formed. The outer surface 85 occupies a considerable part of the widthwise length of the protrusion, and is joined to the side surfaces 86 inclined at both ends. The side surfaces 86 are inclined so as to approach each other from both ends 83. On the outer surface 85, a substantially straight upper surface 87 extending between the inclined side surfaces 86 is formed.

The female contour (or recess) 82 will be described in detail. The connecting portion of the female contour 82 and the flat surface 71 is a substantially parallel end portion 92 that passes through a round corner and a substantially parallel side end portion that is joined to the end portion 92. 91 and. Thereby, the female contour 82 formed on the plane 71
The opening has a substantially rectangular shape, and its center line is provided so as to match the center line of the valley between the adjacent male support portions 72. The shape of the female contour 82 is defined by a pair of opposing side surfaces 93 that are joined to the side end portion 91 and project downward from the side end portion 91. The facing side surfaces 93 are a pair of facing side surfaces 94 protruding downward from the end portions 92, respectively.
To join. The opposing side surfaces 93 are inclined inward as they approach each other and project downward. Further, the opposite side surfaces 94 are also inclined inward as they protrude downward. The opposite side surfaces 93 and 94 are joined to a substantially flat bottom surface 95 through round corners. The bottom surface 95 is provided at a position below the plane 71 with a considerable distance. That is, the bottom surface 95 extends downward from the plane 71,
It is provided at a position spaced apart from the height of the male support portion 72 or the male contour 81.

As shown in FIG. 13, the female contours or recesses 82 are alternately arranged with the male contours 81. The contours 81 and 82 are arranged so as to have a substantially vertical positional relationship. Further, the female contour 82 is formed at the innermost end portion 84 (that is, the platform portion 7).
6 is provided so as to project inward in the longitudinal direction on the side of the male support portion 72 beyond the end portion 84) closest to 6. When viewed from above, as shown in FIG. 13, a position distant from the platform portion 76 in the longitudinal direction is formed by the male contour 81 and the end portions projecting inward (left side) of the pair of female contours 82 straddling the male contour 81. A shallow groove or U-shaped contour is formed which opens to the side of the platform 76 and partially surrounds it.

As shown in FIG. 15, the bottom forming surface 63 provided on the upper die 61 has substantially the same shape as the upper molding surface 64 except that it is vertically inverted. That is, the flat surface 71 ′ of the bottom molding surface 63 is substantially parallel to the flat surface 71 of the lower mold and has the same shape. Further, the recess 72 ′ formed on the bottom forming surface 63 is open upward from the flat surface 71 ′, but matches the shape and size of the male support portion 72 provided on the lower mold 62. Further, the upper mold 61 is provided with rows of material deformation contours 81 'and 82' alternately. The female contour 81 'is a recess that opens upwards from the flat surface 71', and its size and shape are such that it fits effectively with the male contour 81 of the lower mold. Similarly, the male contour 82 'also constitutes a male projection portion projecting downward from the flat surface 71', and the arrangement, size, and shape of the male contour portion 82 'are such that they fit into each other when the mold is closed. It is adapted to match the contour 82. These male contours 82 'are longer (when measured down from the plane 71') than the depth of the recess 72 '. The arrangement, size, and shape of the recess 72 ′ and the female contour recess 81 ′ formed in the upper mold are such that when the molds 61 and 62 are closed, the male support 72 and the male contour 81 facing each other are fitted. Is set to do. However, the recesses of these upper molds 61 are slightly larger than the male projections of the lower molds so as to match the thickness of the carrier plate thin plate material between the molds. Similarly, the position, size, and shape of the male contour 82 'of the upper mold is such that the female contour 8 of the lower mold is such that it fits effectively between the molds.
It agrees with 2. The female contour 82 is slightly larger than the male contour 82 'to match the thickness of the carrier plate material between the dies.

The upper mold 61 in the illustrated or preferred embodiment comprises three upper mold parts 61 A, 6
It is preferably composed of 1B and 61C. All of the mold parts are independently movable vertically between the open position and the closed position with respect to the lower mold 62. The upper mold parts 61A, 61B, 61C are each independently vertically movable by, for example, a conventional air or nitrogen pressure cylinder. Then, the mold part is such that the upper mold part 61A moves downward to the initial closed position to clamp the workpiece W between the mold part 61A and the lower mold 62, and the main rib support recess 73 ' Each is slidably adjacent and positioned to fit. Upper mold part 61 in the middle
The shape of B is such that the ribs 18 are deformed to form tapered ribs, platforms, and flat end flanges. Further, contours 81 'and 82' are formed on the surface of the upper mold component 61C. The upper mold parts 61B and 61C are formed independently of each other and can be moved individually to maximize the degree of freedom of use during the stamping work, but the mold parts 61B and 61C can be moved simultaneously or with a single metal. It goes without saying that they may be combined so as to be configured as mold parts.

When deforming the rib 18 end of the workpiece W, the end of the workpiece is supported and arranged on the upper molding surface 64 of the lower mold 62. The position of the carrier member can be adjusted by abutting the end of the carrier member against the shoulder 78. In this arrangement, the male support portion 72 projects toward the rib 18 at a position away from the free end of the workpiece W, and supports and engages with it. The male contour 81 also projects toward the inside of the rib. Then, the upper mold 61 is
It moves downward to the closed position with the lower mold 62. When the mold parts 62B, 62C are moved to close, the rib 18 ends of the unsupported portion are deformed to form a tapered rib portion 32 that mates with the projecting flat platform portion 41. The platform portion 41, in turn, mates with a flat end flange portion 31 extending across the width of the workpiece. In addition, when the contours 81-81 'and 82-82' fit together, the material of the workpiece is deformed, and a plurality of hollow three-dimensional deformed portions 97, 98 are formed at the ends of the deformed workpiece. Is formed. The deformed portion 9
7, 98 respectively project from the bottom plane of the workpiece in the vertical direction,
Staggered in rows extending across the workpiece near the free end. Male contour 8
1 and the female contour 81 'are fitted to each other to form the deformed portion 97, and the female contour 8
The deformed portion 98 is formed by fitting the 2 and the male contour 82 '.

As shown substantially in FIG. 18, after the workpiece is deformed between the molding dies 61 and 62 to form the deformed portions 97 to 98, the workpiece W is then cut at the cutting surface 99 in FIG. Shear or cut. The deformed disposal end 102 between the cutting surface 99 and the end 100 is then scrapped. The portion cut by the cutting surface 99 becomes the free end of the luggage carrier member.

In the stamping mold according to the preferred embodiment of the present invention, the cross-section of the male contour 81 by the upper surface 87 and the slanted end face 86 is such that the rib 18 is provided when the end of the workpiece is in supporting engagement with the lower mold 62. The rib 18 has a shape that substantially coincides with the inside of the rib 18 so as to engage with the inner side surface. In addition, the pair of male contours 82 ′ of the upper mold 61 are positioned so as to straddle the male contours 81 immediately opposite to each other when deformed, and the male contours 82 ′.
The'bottom surface 101 'preferably projects downwardly from the position of the plane 71' at a distance slightly greater than the height 103 of the rib 18, which in the preferred embodiment is, for example, about 2-3 mm. Also, the height 103 is substantially equal to the recess 72 'that receives the rib protruding upward from the flat surface 71'. These relationships, and in particular the special downward length of the male contour 82 ', assist in proper tensioning of the metal sheet and, in particular, the displacement (movement) of excess material when deforming the sheet metal as described below. be able to.

The stamping of the sloping taper ribs 32, the adjacent platform 41 and the rib ends forming the flat end flange 31 will be briefly described.

If the thickness of the workpiece W over the entire cross section of the valley 19 and the rib 18 is substantially uniform, extra material is generated when the rib end 35 is deformed. The excess material should be effectively removed or removed so that the outer surfaces of the tapered rib portion 35, the platform 41, and the end flange 31 are substantially even and free of wrinkles and scratches.

Therefore, the workpiece W is brought into contact with the shoulder portion 78 for proper positioning and engaged with the lower die 62. The position is a position where the male support portion 72 and the male contour 81 project upward and are supported and engaged with the lower surface of the rib 18. First, the upper mold 61
Move A downwards to secure the workpiece on the lower mold. Then, the upper mold part 61C is moved downward to bring the bottom surface 101 'of the male contour 82' into contact with the top surface of the valley portion 19 (first contact). Even when the bottom surface 101 ′ of the male contour 82 ′ contacts the valley portion 19 (that is, the first contact position), the molding surface 105 formed on the lower surface of the upper mold (component?) 61 B is still the upper surface of the rib 18. It is located above 25.

The upper die part 61C is further moved from its contact position to the lower die side (ie, 2 to
If the movement is continued (3 mm), the male contour 82 'and the laterally extending male contour 81 between them deform the valley 19 below the male contour 82' downward. Further, the rib 18 that comes into contact with the male contour 81 is pulled laterally over the male contour 81, and the upper portion of the anvil is partially deformed. As a result, the first metal tension is performed, that is, the metal tension is pulled away from the main rib supporting portion 73 toward the longitudinal male contour 81 side. At this time, the molding surface 105 of the upper mold part 62B is also moving and contacts the upper surface 25 of the rib 18. Further, when the upper mold parts 61B and 61C are simultaneously moved downward, the upper surfaces 25 of the ribs engaging with the forming surface 105 are pressed downward. Then, when gradually moving downward, the rib inclined portion 75 ′ and the platform forming surface 76 ′ of the upper mold part 61B gradually move to the rib side and deform the rib downward. When the ribs, in particular the longitudinal section between the main support 73 and the male contour 81, is deformed downwards, the material of this section is pulled in the longitudinal direction. Since the upper deformed portion 97 between the male contour 81 and the opposing female contour 81 'is gradually deformed, this tension occurs around the longitudinal side of the male contour 81. At the same time, the male contour 82 'gradually deforms the valley portion 19 toward the female contour 82, and the deformed portion 98 is formed. By this cooperation, the excess material generated from the deformed rib end portion is not only pulled away from the tapered rib portion toward the longitudinal female contour 82 side but also stretched and pulled laterally. This results from the fact that there is a female contour 82 on the side opposite the rib and that the female contour 82 cooperates with the male contour 81 between the female contours 82. This overall mating effect is due to the cooperation of the upper and lower molds, in particular the fact that the pair of male contours 82 'of the mold part 61C provide the first lateral tension across the male contour 81 and the rib top surface. The upper mold part 61B that contacts the longitudinal part and the lateral part, which results in the formation of the deformed parts 97, 98. . Therefore, it is effective in removing excess material from the deformed rib ends, and includes the tapered rib portion 32, the platform 41, and the end flange 3.
1 has a minimum thickness variation, especially wrinkles and surface irregularities. This excess material is used to effectively form the deformed portions 97, 98 so that the majority of the excess material extends from the cutting surface 99 to the free end 100 of the workpiece disposal end 102.
Be moved to. The deformed disposal end 102 is then cut from the carrier member along the cutting surface 99 and disposed of as scrap.

Now, FIGS. 20 to 22 show modified stamp dies. This incorporates all of the features of the mold 61 of FIGS.
At 22, the same reference numbers are used to represent elements corresponding to the molds of FIGS.

In the mold of FIGS. 20 to 22, the female contour 10 is further formed on the upper forming surface of the lower mold.
9 is provided. The female contour 109 is a recess opened downward from the plane 71. The female contour or the recess 109 is formed at a portion between the male contour 81 and the end of the rib supporting portion 72. One end of the female contour 109 is formed adjacent to the side along the inner end portion 84 of the male contour 81, substantially parallel thereto. Further, both ends of the female contour 109 are open to the end side of the female contour 82. The cross section of the female contour 109 (that is, the vertical surface of the rib supporting portion 72 in the longitudinal direction) is substantially round or arched. The depth of the female contour 109 is considerably shallower than the depth of the female contour 82. Further, the depth distance is considerably shorter than the height of the male contour 81. This recess 109
Is shallower and in open communication with the end of the deeper female contour 82, a generally U-shaped groove or recess is formed that spans the three sides of the male contour 81.

The lower molding surface of the upper mold is provided with a male contour 109 ′ protruding downward. Its male contour extends longitudinally along the edges of the female contour 81 ', its ends being at the ends 92
It is joined to '. The height of the male contour 109 'is much lower than the height of the male contour 82', especially its size so that it fits effectively when the mold is in the closed position and the sheet metal is sandwiched therebetween. And substantially coincides with the female contour 109.

In the modified mold apparatus of FIGS. 20-22, the female contour 82 contacts the valleys of the workpiece W while the male contour 109 ′ contacts the upper surface of the rib 18. Then, the workpiece W is first deformed by the female contour 82, and further, the rib upper surface is deformed by the protrusion 109 ′. Therefore, the thin sheet metal material is pulled in the horizontal and vertical directions near the male contour 81. Other deformations and pulling of rib ends are performed in the same manner as above.
In this way, since the male contour 109 'is additionally provided and projected toward the female contour 109 side,
Additional deformation is achieved by effectively joining one end of the deformed portion 97 and outlining it in the opposite direction (i.e., vertically downward) and extending toward the tapered rib portion. This effectively pulls excess material away from the deformed rib ends towards the longitudinal scrap disposal end 102 side.

Given the overall performance of the modified molds of FIGS. 20-22, it is anticipated that the platform 76 associated with the deformed rib ends may be omitted. As a result, the tapered rib inclined portion 7
5 and the flat end flange 71 can be joined directly. In this way, the total length of the rib ends can be shortened and the amount of deformable material can be reduced. The previous excess material used to form the platform 76 is pulled longitudinally toward the scrap disposal end 102 side,
A deformed portion can be formed between the concave portion 109 and the protruding portion 109 '.

Now, in the improved carrier member and the method for manufacturing the same according to the present invention, the carrier member is preferably manufactured from a thin steel sheet having a maximum thickness of about 1.0 mm. Lower thicknesses are preferred, and in one embodiment a thickness of about 0.85 mm is preferred. Further, the corners in the longitudinal direction where the rib side surfaces join the rib upper surface, or the corners where the rib side surfaces join the bottom portion or the valley portion are preferably configured with a considerably large radius, for example, about 20 mm radius. This is because it minimizes the material at the cross-section lines of the ribs and also minimizes the rate of fracture, thus increasing the accuracy of cold work during roll forming. Thereby, the redistribution of the material when deforming the rib ends can be carried out more satisfactorily. In addition, the top surface of the raised platform 41 in the preferred embodiment is positioned above the bottom surface of the trough, which is about 3-4 times the thickness of the sheet metal material. The elevation of the platform position is about 1/4 to 1/5 of the rib height.

In the method of forming this vehicle bed with the rib ends deformed as described above, the roll-formed workpiece is first cut to the length of the bed member (or at the same time), and then one or both ends are cut. Deformation work may be performed. After the deforming operation, the scrap disposal end 102 is removed.

Now, in a method intended to manufacture a carrier member, after cutting a roll-formed workpiece to the length of the carrier member as schematically shown in FIG. 11, the workpiece is rotated 90 degrees horizontally. Then, it is conveyed to the stamping press while pointing in the width direction. The press is almost identical on both sides (but mirror images)
It is equipped with a pair of stamping dies, which simultaneously act on both ends of the workpiece W and effectively deform it. After the both ends of the work piece are deformed into the shape as shown in FIG. 12, the work piece is moved to the next working unit while being oriented in the width direction again. A pair of cutting devices are located on opposite sides of adjacent work stations to simultaneously cut both ends of the workpiece, producing removable scrap disposal ends 102. The carrier member is then moved to perform other processing as needed.

As an alternative forming method, the rib end deformation according to the invention can also leave the roll-formed carrier member coupled to the continuous profile P fed from the roll mill. In this variant, the free tip end of the profile is fed into a stamping die, which deforms it and cuts the scrap part. Then cut from the continuous profile and deform the other end if necessary.

As another method, in the method of deforming the rib ends of the carrier member, there is a method of deforming both ends when the profile P sent from the roll mill is continuous. In this state, the mold has two sets of opposed deforming surfaces that are spaced apart. For example, as shown in FIGS. 13 to 19, the upper and lower molds have deformed contours 81, 8
Forming surfaces 72, 72 'are provided which project longitudinally horizontally away from both sides of the two rows. Then, the profile is fed between the molds to simultaneously form the rib end at the back end of one carrier member and the rib end at the tip of the adjacent carrier member. Then, the intermediate scrap portion joining the two end portions is cut and removed at two positions. The backing carrier member is then advanced the length of the workpiece and the next forming operation is performed to properly deform the other end of the carrier member.

If the carrier member is still integral with the continuous roll-formed profile and deforms the rib ends, it is probably necessary to momentarily stop the profile so that the rib stamping operation can be performed. Be recognized.

Although the preferred embodiments according to the present invention have been disclosed in detail for purposes of illustration,
Variations or modifications (including reconfigurations) of the disclosed apparatus are considered within the scope of the invention.

(Industrial Applicability) As described above, according to the present invention, when a rib required for a vehicle carrier member is formed into a thin plate, the thickness of the thin plate is equal to the entire cross section of the thin plate. A high degree of uniformity is maintained. And, by doing so, a high level of strength, performance and beauty can be achieved.

[Brief description of drawings]

FIG. 1 is an exploded perspective view showing the basic components of a conventional truck pan or bed member.

FIG. 2 is an enlarged partial cross-sectional view of an improved end structure of a roll-formed carrier member previously developed by the assignee and its connection to a lateral sill.

[Figure 3] FIG. 3 is a partial cross-sectional view of the roll-carrying carrier member taken along line 3-3 of FIG.

FIG. 4 is a partial cross-sectional view of the tapered rib portion of the load carrier member roll-formed by line 4-4 in FIG.

[Figure 5] It is the fragmentary sectional view which changed FIG.

FIG. 6 is a partial perspective view showing the structure of an improved taper rib portion in the rib of the roll-shaped carrier member according to the present invention.

[Figure 7] FIG. 7 is a partial side view of a tapered end portion of a rib taken along line 7-7 of FIG. 6.

[Figure 8] FIG. 8 is a top view of the rib end portion of FIG. 7.

[Figure 9] 9 is a partial cross-sectional view taken along line 9-9 of FIG. 8.

[Figure 10] FIG. 10 is a partial sectional view taken along line 10-10 of FIG. 9.

FIG. 11 FIG. 4 is a process flow chart showing an improved molding process according to the present invention.

FIG. 12 is a partial perspective view of the improved load carrier member of the present invention, in particular, the tapered rib portion of the load carrier member rib as viewed from above.

FIG. 13 is a partial plan view showing an upper molding surface of a lower mold used for molding the taper rib end portion of the carrier member.

FIG. 14 It is a partial perspective view which looked at the upper molding surface of a lower metallic mold from above.

FIG. 15 It is a partial perspective view of the lower molding surface of the upper mold seen from below.

16 is an exploded cross-sectional view taken along line 16-16 of FIG. 13, showing the shapes of the upper and lower molding surfaces and the arrangement of the ends of the carrier member before the deformation of the carrier member.

FIG. 17 FIG. 17 is a sectional view taken along line 17-17 of FIG. 16.

FIG. 18 is an exploded cross-sectional view similar to FIG. 16, but showing the shape of the end of the carrier member after being deformed by the mold.

FIG. 19 FIG. 19 is a sectional view taken along line 19-19 of FIG. 18.

FIG. 20 It is a figure similar to FIG. 13 which changed the upper surface of a lower metal mold | die.

FIG. 21 It is a figure similar to FIG. 16 which changed the same upper and lower mold surface as the apparatus of FIG.

FIG. 22 FIG. 22 is a cross-sectional view of the modified mold surface along line 22-22 of FIG. 21.

[Procedure for Amendment] Submission for translation of Article 34 Amendment of Patent Cooperation Treaty

[Submission date] January 28, 2002 (2002.28)

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be amended] Claims

[Correction method] Change

[Contents of correction]

[Claims]

─────────────────────────────────────────────────── ─── Continued front page    (81) Designated countries EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, I T, LU, MC, NL, PT, SE, TR), OA (BF , BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, G M, KE, LS, MW, MZ, SD, SL, SZ, TZ , UG, ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AE, AG, AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, B Z, CA, CH, CN, CR, CU, CZ, DE, DK , DM, DZ, EE, ES, FI, GB, GD, GE, GH, GM, HR, HU, ID, IL, IN, IS, J P, KE, KG, KP, KR, KZ, LC, LK, LR , LS, LT, LU, LV, MA, MD, MG, MK, MN, MW, MX, MZ, NO, NZ, PL, PT, R O, RU, SD, SE, SG, SI, SK, SL, TJ , TM, TR, TT, TZ, UA, UG, US, UZ, VN, YU, ZA, ZW (72) Inventor Tyler Gregory Bee.             United States 48307 Lo, Michigan             Chester Hills Longview Ave             2550 Address

Claims (20)

[Claims] 1. A plurality of groove-shaped ribs which are opened downward and which extend in the longitudinal direction substantially in parallel with the carrier member and end at the front and rear ends in the width direction are provided with a space between them laterally. The rib near one end of the member is deformed to taper downwardly from the upper surface of the rib at a full height to form a downwardly sloping taper rib portion that joins with a flat end flange, the end flange being the In a roll-formed integrally formed vehicle carrier member that extends in the width direction over the entire width and serves as an end portion of the carrier member, the tapered rib portion includes the rib upper surface having a complete height and the flat surface. A slanting side surface that is slanted downward between the end surface and the end flange, and the central surface portion of the slanting end surface is offset vertically below the side end portion that connects the central surface portion and the rib side surface of the groove-shaped rib. Roll-formed one Body forming vehicle carrier member. 2. The flat end flange is provided with a raised platform extending in the width direction over the entire width of the center surface portion, and one end of the raised platform is joined to a lower end of the center surface portion. The luggage carrier member according to claim 1, wherein the other end is provided apart from the luggage carrier member end portion. 3. The raised platform is a substantially flat surface that extends substantially parallel to the end flange and is offset upward from the end flange, and a recess is provided under the raised platform. The carrier member described in. 4. The upper end of the central surface portion of the upper surface that slopes downward is joined to the rib upper surface through a smoothly curved upper end portion that extends over the entire width of the rib upper surface, and the rib is provided on the upper end portion. The convex first curved portion, which is joined to the upper surface and is bent downward smoothly to be coupled with the concave curved portion, is provided, and the concave curved portion is joined to the upper end of the central surface portion. The luggage carrier described. 5. A plurality of groove-shaped ribs which are opened downward and which extend in the longitudinal direction substantially parallel to the luggage carrier member and terminate at the front and rear end portions in the width direction are provided with a lateral gap between them. The rib near one end of the member is deformed to taper downward from the rib upper surface at a full height to form a downwardly sloping taper rib portion that joins with a flat end flange, the end flange being the width of the carrier member. In a roll-formed integrally formed vehicle carrier member that extends in the width direction over the whole and serves as one of the ends of the carrier member, one end of the inclined end surface of the taper rib portion has a complete height. The rib is joined to the upper surface of the rib and is inclined downwardly from the rib, and the other end is joined to one end of a raised flat platform provided on the flat end flange and spaced slightly above the end flange. Cage, front The flat platform extends longitudinally from the sloping end surface to the rear end, the rear end approaching and distant from the carrier member end, and the width of the platform is determined by the width of each rib. The roll-formed integrally formed vehicle carrier member that substantially matches the width of each of the ribs and is substantially aligned with the ribs. 6. The carrier member according to claim 5, wherein the thickness of the carrier member including the rib, the inclined end surface, the platform, and the end flange are all the same. 7. The platform has a large, generally horizontal, flat upper surface, the upper surface occupying substantially the same extent as the platform.
The carrier member described in. 8. The platform includes a side edge that bulges the platform above the end flange, the side edge being substantially aligned with a rib side surface of the grooved rib, and the rib side surface. The luggage carrier member according to claim 7, which is continuous with. 9. The tapered end surface of the tapered rib portion includes a large substantially flat center surface portion that slopes downwardly from the upper surface of the rib of full height to join with the raised platform, and is adjacent. A full-height rib with a side edge that slopes downwardly from the top surface and joins the platform adjacent an opposite platform side edge, wherein the mid-plane portion is vertically offset downward from the side edge. Is
The vehicle carrier according to claim 8, wherein a cross section of the side end portion has a groove shape curved in a substantially convex shape that is coupled to a side surface of the groove rib. 10. A longitudinal direction for forming a three-dimensional workpiece member having a flat bottom surface and a plurality of parallel groove-shaped ribs projecting upward from the bottom surface and opening downwards in parallel. A step of roll forming a large thin steel sheet of, wherein the ribs extend in the longitudinal direction over the entire workpiece member, and the ribs are flattened / deformed to form the ribs. A step of deforming a portion near one end across the width direction of the workpiece member to form a taper rib portion that inclines downward, the taper rib portion closing each rib end and ending with a flat end flange. The end flange is substantially coplanar with the bottom surface of the workpiece and extends in the width direction over the entire vicinity of the one end of the workpiece. And a step of deforming the rib end portion downward to the bottom surface side. (1) From the rib upper surface, (2) Joined to the inclined end surface of the rib inclined downward on the bottom surface side, and (2) joined to the lower end of the inclined end surface, projecting in the longitudinal direction from the inclined end surface at a position where it rises a short distance above the bottom surface, Forming a substantially flat and horizontal platform surface that terminates, and (3) a flat end flange that is located substantially coplanar with the bottom surface and projects away from the remote end of the platform in the longitudinal direction. In the step of deforming, when the rib end portion is deformed, the rib end portion is pulled in the longitudinal direction, excess material generated by the deformation of the rib portion is moved away from the taper rib portion in the longitudinal direction, and wrinkles are generated. To Comprising a step of the small limited, a method of forming a vehicle loading platform member integral molding. 11. A step of providing the workpiece member with an integral disposable portion having a predetermined length and joined to the workpiece member, the portion being longitudinal to the portion to be deformed. The step of extending across the width direction of the entire workpiece member adjacent to the site so as to be in the position of adjoining and joining, and the disposable site under the bottom surface side simultaneously with the rib end deformation. Deforming the transverse rib portion, at substantially the same time, deforming the bottom surface downward in a direction opposite to the rib portion, away from the bottom surface, in a region extending between the rib portions, thereby deforming the workpiece member. 11. The method of claim 10, further comprising: pulling excess rib end material longitudinally toward the disposable site. 12. The method of claim 11, comprising the step of laterally cutting the carrier member along a line at the end of the flat end flange to separate the carrier member from the disposable site. Method. 13. The rib portion of the disposable portion is deformed downward in the width direction on a male contour projecting upward from the bottom surface to form a raised hollow protrusion portion at the disposable portion. The method of claim 11, comprising steps. 14. A pair of hollow deformable portions projecting downward, which are located so as to straddle the hollow projecting portion substantially laterally, by deforming the bottom surface of the disposable portion downward, and projecting the projecting portion. The method according to claim 13, wherein the portion and the deformed portion respectively project from the bottom surface in opposite directions. 15. The deformation of the bottom surface forming the deformed portion is performed before deforming the rib portion forming the hollow protruding portion, and the deformation forming the protruding portion and the deformed portion is not performed. 15. The method according to claim 14, which is performed simultaneously thereafter. 16. The deformed portion extends in the longitudinal direction of the rib portion, and the deformed portion has a width direction substantially equal to the width of the bottom surface where the valley portion between adjacent rib portions is formed. 15. The method of claim 14, wherein the method is located within the width of the. 17. The hollow protrusion extends in the width direction of the rib, and the length of the protrusion in the width direction substantially matches the width of each rib, and is aligned in the longitudinal direction. The method of claim 16, wherein the method is performed. 18. A vertical workpiece for forming a three-dimensional workpiece member having a flat bottom surface and a plurality of parallel groove-like ribs projecting upward from the bottom surface and being open downwards and arranged substantially sideways. A step of forming a thin steel sheet having a large direction, wherein the rib extends in the longitudinal direction over the entire workpiece member, and a stamping press equipped with opposed vertically movable upper and lower forming dies. The step of providing the mold with a facing molding surface suitable for deforming by engaging the elongated portion of the workpiece member between the molds; Forming a plurality of vertically projecting rib supporting portions suitable for supporting engagement with the inner surface side of each rib of the workpiece on the molding surface of the mold, the rib supporting portion The step of providing an inclined end portion that inclines downward from the upper surface of the rib support portion at one end of the section, and the step of forming a vertically projecting male contour on the molding surface of the one die member. The male contour is aligned with the slanted end of the rib support portion in the longitudinal direction and is spaced from the male contour, and a pair of females are provided laterally so as to straddle the male contour. The step of arranging between the contours, the female contour projecting vertically to the molding die side in a direction opposite to the male contour projecting vertically, and the molding surface of the other die member. And a step of providing a plurality of rib forming recesses, wherein the rib forming recesses are aligned substantially vertically with the one rib supporting portion, and the rib supporting portion of the one molding die is fitted therein. Formed to accept, and further The other mold is provided with a vertically projecting male contour receiving concave portion and a pair of convex portions that laterally straddle the male contour receiving concave portion and vertically project in the opposite direction, and the male contour receiving concave portion and the convex portion are provided. The step of forming the part into a size and shape that are aligned substantially vertically with the male contour and the female contour of the one die and are engaged with and engaged with the male contour and the female contour, and the molded workpiece A step of placing a member between the open molds, wherein the ribs of the first elongated portion of the workpiece member surround the inclined end of the protruding rib support of the one mold. A second elongate portion disposed adjacent to and integrally joined to the first elongate portion, the ribs of the second elongate portion each Said step being arranged in supporting engagement therewith around said male contour And a step of moving the first and second molding dies to the other side, respectively, and engaging with the end portion of the workpiece member between the facing forming surfaces, the first and second workpiece members. The first rib is formed by vertically pressing the rib portion of the second elongated portion.
The ribs of the elongated portion are deformed on the slanted end, and the ribs of the second elongated portion are deformed on each of the male contours to separate longitudinally from the slanted end. And continuously moving the first and second molds inward so as to pull the extra material on the male contour side. 19. The male contour is laterally shaped to deform two second protrusions laterally straddling the first protrusion formed around the male contour and projecting in the opposite vertical direction. A step of vertically deforming the bottom surface of the valley portion of the second elongated portion straddling the groove, wherein the protruding portion pulls excess material in the longitudinal direction from the first elongated portion to the second elongated portion. Item 18. The method according to Item 18. 20. The method of claim 19, wherein the step of forming the second protrusion is performed for a short time before deforming the upper surface of the rib.